Fabrication and mechanism of poly(butylene succinate) urethane ionomer microcellular foams with high thermal insulation and compressive feature

Mechanical, Crystallization, Rheological, and Supercritical CO2 Foaming Properties of Polybutylene Succinate Nanocomposites: Impact of Carbon Nanofiber Content

As a substitute for conventional polymers for the preparation of biodegradable microcellular polymeric foams, polybutylene succinate (PBS) presents one of the most promising alternatives. However, the low melt strength of PBS makes it difficult to produce high-performance microcellular foams. This study aimed to improve the melt strength of PBS and explore the mechanical, thermal, crystalline, rheological, and supercritical CO2 foaming properties of PBS nanocomposites by using carbon nanofibers (CNFs). This study found that nanocomposites containing 7 wt% CNF exhibited the highest tensile strength, Young's modulus, and bending strength. Moreover, the CNF nanofillers were well dispersed in the PBS matrix without significant agglomeration, even at high filler concentrations. Furthermore, the nanocomposites demonstrated improved melting temperature and crystallinity compared with pure PBS. The rheological analysis showed that the addition of CNFs significantly increased PBS viscosity at low frequencies due to the interaction between the PBS molecular chains and CNFs and the entanglement of CNFs, resulting in a more complete physical network formation when the CNF content reached above 3 wt%. During the supercritical CO2 foaming process, the addition of CNFs resulted in increased cell density, smaller cells, and thicker cell walls, with good laps formed between the fibers on the cell walls of nanocomposite foams. Moreover, the electrical conductivity and electromagnetic interference (EMI) shielding properties of the foamed material were studied, and a nanocomposite foam containing 7 wt% CNF showed good electrical conductivity (4.5 × 10-3 S/m) and specific EMI shielding effectiveness (EMI SE) (34.7 dB/g·cm-1). Additionally, the nanocomposite foam with 7 wt% CNF also exhibited good compression properties (21.7 MPa). Overall, this work has successfully developed a high-performance, multifunctional PBS-based nanocomposite foam, making it suitable for applications in various fields.

Improved thermal insulation and compressive property of bimodal poly (lactic acid)/cellulose nanocomposite foams

In this work, an innovative PLA/CNF nanocomposite foam with a bimodal cell structure is prepared by a simple one-step depressurization foaming process using only supercritical carbon dioxide (ScCO₂) as the foaming agent. Only at a specific foaming temperature, PLA/CNF nanocomposites foam with a bimodal cell structure could be obtained. According to the different crystallization kinetics and nucleation efficiency of samples, it was inferred that the crystallization rate and phase interface would affect the cell structure. The prepared PLA/CNF nanocomposite foam with a bimodal cell structure had an expansion ratio as high as 20 times and thermal conductivity of 0.041 w m^-1 k^-1, which exhibited low density and excellent thermal-insulation property. Meanwhile, the PLA/CNF nanocomposite foam exhibited excellent compression performance due to the presence of CNFs, which showed promising application in packaging and construction materials.

Pressure-induced flow processing behind the superior mechanical properties and heat-resistance performance of poly(butylene succinate)

We propose a pressure-induced flow (PIF) processing method for the simultaneous enhancement of strength, toughness, and heat resistance of biodegradable poly(butylene succinate) (PBS). The pressure and temperature were systematically adjusted to optimize the tensile strength of PBS. Under the optimized processing conditions, the structured PBS was characterized by relatively high strength of 89.5 MPa, toughness of 21.4 kJ·m−2, and improved heat resistance without deterioration of much of its ductility. Microscopic analyses witnessed denser and highly oriented crystalline domains along the flow direction caused by PIF processing. Detailed crystallization analysis made by 2D-WAXD and 2D-SAXS unraveled the extremely ordered PBS domains, which were featured by a significant increase in the orientation degree from 0.25 for the reference to 0.73 for PIF-processed PBS. Such a highly ordered microstructure substantially boosted the degree of crystallinity and heat-resistance temperature of PBS. We believe that our findings would offer a facile, green, and cost-effective approach for fabricating biodegradable polymers with outstanding properties and performance.

Effect of Foaming Formulation and Operating Pressure on Thermoregulating Polyurethane Foams

The synthesis of rigid polyurethane (RPU) foams containing thermoregulatory microcapsules has been carried out under reduced pressure conditions with a new foaming formulation to reduce the final composite densities. These optimized RPU foams were able to overpass the drawbacks exhibited by the previous composites over the studied temperature range, working as insulating and thermal energy storage materials. The change in the formulation allowed to decrease the final foam density and enhance their mechanical strength. The effect of the operating pressure (atmospheric, 800 mbar, and 700 mbar) and microcapsules content (up to 30 wt%) on the physical, mechanical, and thermal PU foam properties was studied. The reduction of the pressure from atmospheric to 800 mbar did not have any effect on the cell size, strut thickness, and compression strength 10% of deformation, the Young modulus being even higher at 800 mbar. Nevertheless, a strong impact on the microstructure and mechanical properties was observed for the foam composites obtained at 700 mbar. A deleterious impact on the RPU foams thermal conductivity was observed when using low-pressure conditions. Thermal analyses showed that a composite able to work as heat accumulator and thermal insulation both at transient and at steady state was achieved.

Characteristics of Microcellular Foamed Ceramic Urethane

Ceramics are non-metallic inorganic materials fabricated from natural or high-purity raw materials through heating and cooling processes. Urethane is a three-dimensional plastic with both elasticity and chemical resistance; moreover, it is used as a rubber substitute. The use of both materials in various applications is gradually increasing. However, as ceramics and urethane have distinctly different properties, this prompted questions regarding the properties of a material that is fabricated using both materials. Therefore, we studied the characteristics of a composite material fabricated through physical foaming using a batch process. The process was conducted with gas saturation, foaming, cooling, and curing. When a specimen of 2 mm thickness was saturated in 5 MPa of CO₂ for 2 h, the solubility was 6.43%; when foaming was carried out at a temperature of 150 °C in boiled glycerin, the foaming ratio, cell size, cell density, and void fraction were found to be 43.62%, 24.40 µm, 9.1 × 10⁷ cells/cm², and 22.11%, respectively. Furthermore, the volume increased by 102.96%, color changed from dark to light gray, hardness decreased by 24%, thermal diffusivity increased by 0.046 mm²/s at 175 °C, and friction coefficient decreased to 0.203. Thus, the microcellular foamed ceramic urethane exhibits a larger volume, lighter weight, and improved thermal conductivity and friction coefficient.

The effect of polytetrafluoroethylene particle size on the properties of biodegradable poly(butylene succinate)-based composites

Poly(butylene succinate) (PBS)/polytetrafluoroethylene (PTFE) composites, including three types of PTFE powders, were prepared by melt blending using a HAAKE torque rheometer. Microcellular foams were successfully fabricated by batch foaming with supercritical fluids (scCO₂). The effects of PTFE powder type on crystallization, rheological properties and foaming behavior were studied. PTFE L-5 and PTFE JH-220 powders showed good dispersion in the PBS matrix, and PTFE FA-500 powder underwent fibrillation during the melt blending process. All three PTFE powders gradually increased the crystallization temperature of PBS from 78.2 to 91.8 ℃ and the crystallinity from 45.6 to 61.7% without apparent changes in the crystal structure. Rheological results revealed that PBS/PTFE composites had a higher storage modulus, loss modulus, and complex viscosity than those of pure PBS. In particular, the complex viscosity of the PBS/P500 composite increased by an order of magnitude in the low-frequency region. The foamed structure of PBS was obviously improved by adding PTFE powder, and the effect of fibrillated PTFE FA-500 was the most remarkable, with a pore mean diameter of 5.46 μm and a pore density of 1.86 × 10⁹ cells/cm³ (neat PBS foam: 32.49 μm and 1.95 × 10⁷ cells/cm³). Moreover, PBS/P500 foam always guarantees hydrophobicity.

Cell structure and mechanical properties of microcellular PLA foams prepared via autoclave constrained foaming

Microcellular polylactic acid (PLA) foams with various cell size and cell morphologies were prepared using supercritical carbon dioxide (sc-CO2) solid-state foaming to investigate the relationship between the cell structure and mechanical properties. Constrained foaming was used and a wide range of cell structures with a constant porosity of ∼75% by tuning saturation pressure (8–24 MPa) was developed. Experiments varying the saturation pressure while holding other variables’ constant show that the mean cell size and the mean cell wall thickness decreased, while the cell density and the open porosity increased with increase of pressure. Tensile modulus of PLA foams decreased with increasing the saturation pressure, but the specific tensile modulus of PLA foams was still 15–80% higher than that of solid PLA. Tensile strength and elongation at break first increased with increasing saturation pressure up to 16 MPa and then decreased with further increasing saturation pressure (20 MPa and 24 MPa) at which opened-cell structure produced. Compressive modulus, compressive strength, and compressive yield stress also followed the same variation trend. The results indicated that not only cell size plays an important role in properties of PLA foams but also cell morphology can influence these properties significantly.

Nucleation of Poly(lactide) Partially Wet Droplets in Ternary Blends with Poly(butylene succinate) and Poly(ε-caprolactone)

This work presents the first investigation on the crystallization behavior of partially wet droplets in immiscible ternary blends. Poly(lactide), poly(ε-caprolactone), and poly(butylene succinate) (PLA, PCL, and PBS, respectively) were melt blended in a 10/45/45 weight ratio to produce a "partial wetting" morphology with droplets of the PLA minor phase located at the interface between the other two major components. The crystallization process of the higher melting PLA droplets was studied by polarized light optical microscopy, while the other components remain in the molten state. We found that neighboring partially wet droplets nucleate in close sequence. This is unexpected since partially wet droplets display points of three-phase contact and, hence, should not touch each other. Moreover, the onset of poly(lactide) crystallization is frequently observed at the interface with molten PCL or PBS, with a significant preference for the former polymer. The observed sequential droplet-to-droplet crystallization is attributed to the weak partial wetting behavior of the PCL/PLA/PBS ternary system. In fact, the contact between the interfacially confined droplets during crystallization due to their mobility can lead to a transition from a partial to a completely wet state, with the formation of thin continuous layers bridging larger partially wet droplets. This allows crystallization to spread sequentially between neighboring domains. Using a simple heterogeneous nucleation model, it is shown that the nucleation of PLA on either PCL or PBS melts is energetically feasible. This study establishes a clear relationship between the unique partial wetting morphology of ternary blends and the nucleation of the minor component, paving the way to the understanding and control of crystallization in multiphasic polymer blends for advanced applications.

Fabrication of bimodal open-porous poly (butylene succinate)/cellulose nanocrystals composite scaffolds for tissue engineering application

The design of porous tissue engineering scaffold with multiscale open-pore architecture (i.e., bimodal structure) promotes cell attachment and growth, which facilitates nutrient and oxygen diffusion. In this study, a porous poly (butylene succinate) (PBS)/cellulose nanocrystals (CNCs) composite scaffold with a well-defined controllable bimodal open-pore interconnected structure was successfully fabricated. The bimodal open-porous scaffold architecture was designed by synergistic control of temperature variation and a two-step depressurization in a supercritical carbon dioxide (Sc-CO₂) foaming process. The microstructure and properties of the bimodal open-porous PBS/CNCs scaffold, such as morphology, open porosity, hydrophilic and degradation performance, and mechanical compression properties, were analyzed. In the experiments, the scaffold with unimodal pore structure was used for comparison. The results showed that the bimodal open-porous PBS5 scaffold displayed a well-defined bimodal open-pore structure composed of large pore (~68.9 μm in diameter) and small pore (~11.0 μm in diameter), with a high open porosity (~95.2%). In addition, the scaffolds exhibited good mechanical compressive properties (compressive strength of 2.76 MPa at 50% strain), hydrophilicity (water contact angle of 71.7 °C) and in vitro degradation rate. Moreover, in vitro biocompatibility was determined with NIH-3T3 fibroblast cells using MTT assay and live/dead cell viability assay. Results indicated that the obtained bimodal open-porous scaffolds had a good biocompatibility and the viability of cells grown on the scaffolds reached up to 98% after 7th day of culture. Therefore, our work provides new insights into the use of biodegradable polymeric composite scaffolds with bimodal open-pore structure and balanced properties in tissue engineering.

Fabrication of Poly(butylene succinate)/Carbon Black Nanocomposite Foams with Good Electrical Conductivity and High Strength by a Supercritical CO2 Foaming Process

Lightweight, high-strength and electrically conductive poly(butylene succinate) (PBS)/ carbon black (CB) nanocomposite foams with a density of 0.107–0.344 g/cm³ were successfully fabricated by a solid-state supercritical CO₂ (ScCO₂) foaming process. The morphology, thermal and dynamic mechanical properties, and rheological behavior of the PBS/CB nanocomposites were studied. The results indicate that the CB nanofiller was well dispersed in the PBS matrix and the presence of a proper CB nanofiller can accelerate the rate of crystallization, improve the thermal stability, enhance the stiffness, and increase the complex viscosity of PBS/CB nanocomposites. These improved properties were found to play an important role in the foaming process. The results from foaming experiments showed that the PBS/CB nanocomposite foams had a much smaller cell size, a higher cell density, and a more uniform cell morphology as compared to neat PBS foams. Furthermore, the PBS/CB nanocomposite foams also possessed low density (0.107–0.344 g/cm³), good electrical conductivity (~0.45 S/cm at 1.87 vol % CB loading), and improved compressive strength (108% increase), which enables them to be used as lightweight and high-strength functional materials.

Nanocellular Foaming Behaviors of Chain-Extended Poly(lactic acid) Induced by Isothermal Crystallization

Recently, the fabrication of semicrystalline polymer foams with a nanocellular structure by supercritical fluids has been becoming a newly developing research hotspot, owing to their peculiar properties and prospective applications. In this work, a facile and effective isothermal crystallization-induced method was proposed to prepare nanocellular semicrystalline poly(lactic acid) (PLA) foams using CO₂ as a physical blowing agent. Styrene-acrylonitrile-glycidyl methacrylate (SAG) as a chain extender (CE) was introduced into PLA through a melt-mixing method to improve the crystallization behavior and melt viscoelasticity of PLA. The chain extension reaction between PLA and SAG occurred successfully as well as the branching and micro cross-linking structures were generated in chain-extended PLA (CPLA) samples, which were confirmed by Fourier transform infrared spectra, gel fraction, and intrinsic viscosity measurements. Owing to the nucleation effect of branching points and the restricted movement of PLA molecular chains by the formation of branching and/or microcross-linking structures, a large number of small spherocrystals were generated in CPLA samples, which was beneficial to produce nanocells. Nanocellular CPLA foams were prepared successfully, when the foaming temperature was 125 °C. As the SAG content increased, the cell size of various PLA foams decreased from 364 ± 198 to 249 ± 100 nm and their volume expansion ratio increased from 1.15 ± 0.05 to 2.22 ± 0.01 times, gradually. When the foaming temperature increased from 125 to 127 °C, an interesting transition from nanocells to microcells could be observed in CPLA foam with the CE content of 2 wt %. Finally, the formation mechanism of nanocells in various PLA foams was proposed and clarified using a schematic diagram.

Effect of Polymer Blends on the Properties of Foamed Wood-Polymer Composites

The polypropylene (PP)/wood flour (WF) composites were prepared using a co-rotating twin-screw extruder followed by a single-screw extruder foaming system in this paper. Polymers, such as polyolefin elastomer (POE), high-density polyethylene (HDPE) or microcrystalline wax, were blended with PP in the preparation of composites to improve the melt strength. And a cavity transfer mixer was introduced to increase the distribution uniformity of components in composites. Meanwhile, the effect of the polymer blends on the microstructure and mechanical properties of samples was investigated. The experimental results show that the addition of POE and HDPE resulted in the second melting peak in the differential scanning calorimeter (DSC) curves and a great decrease in the cell size was caused by the added POE. However, due to the velocity difference of composites in the die, the shape of bubbles gradually became irregular. Moreover, the impact strength of samples significantly increased by 85% for the added POE and the apparent density decreased by 6.7%. And the minimum Vicat softening temperature of 133.7 °C was obtained when the mass ratio of HDPE to PP was 4/6.

An Effective Flocculation Method to the Kaolin Wastewater Treatment by a Cationic Polyacrylamide (CPAM): Preparation, Characterization, and Flocculation Performance

P(AM-DMC) (PAD) was synthesized by ultraviolet- (UV-) initiated copolymerization with methacryloxyethyl trimethyl ammonium chloride (DMC) and acrylamide (AM) as the monomers and initiator 2,2-azobis [2-(2-imidazolin-2-yl) propane] dihydrochloride (VA-044) as the photoinitiator. Parameters that affect the molecular weight were reviewed by using the single-factor approach. The results showed that the molecular weight (MW) of PAD could come to 7.88 × 106 Da with the optimum polymerization conditions as follows: monomer concentration of 30%, monomer mass ratio m(AM) : m(DMC) of 3 : 1, initiator concentration of 0.6‰, illumination time of 80 min, solution pH value of 4.5, and incident light intensity of 1000 μW cm−2. The PAD was represented by several instruments. The results of FTIR and 1H NMR showed that PAD was indeed polymerized by AM and DMC. The results of TGA showed that PAD was very stable at room temperature while the result of SEM revealed that PAD had a porous structure and rough surface. For PAD used as flocculant in kaolin wastewater treatment, the results confirmed that, at optimal conditions, the turbidity and the floc size d50 could reach to 5.9 NTU and 565.936 μm, respectively, at the optimal conditions (pH = 7.0 and dosage = 2 mg l−1). Kaolin wastewater flocculation test outcome reveals that the PAD with high cationic degree and intrinsic viscosity could boost the charge neutralization and bridging capability. Consequently, the result is an excellent flocculation performance of treating kaolin wastewater.